REAR BRACKET ATTACHMENT Step 5) Step 1) Step 9 ... INSTALLATION INSTRUCTIONS Page 2 KODIAK...

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KODIAK INSTALLATION INSTRUCTIONS Page 2 KODIAK INSTALLATION INSTRUCTIONS Page 3 KODIAK INSTALLATION INSTRUCTIONS Page 4 Installation Instructions Fits: 2002-06 Dodge Ram 1500, 2500, 3500 2002-06 Dodge Ram 1500 Quad Cab For Kodiak Kits #950220000 (front driver side, silver) #950221000 (front passenger side, silver) #950220010 (rear driver side, silver) #950221011 (rear passenger side, silver) #950220100 (front driver side, black) #950221100 (front passenger side, black) #950220110 (rear driver side, black) #950221111 (rear passenger side, black) Hardware in each Kit 1 Step Assembly 1 Left rear mounting bracket 1 Right rear mounting bracket 2 Short angle brackets 1 Fasteners Kit 1 Front adapter mounting bracket KODIAK INSTALLATION INSTRUCTIONS 1422135 / Rev. 0C © 05/08 Kwikee Products Right Rear Mounting Bracket Figure 1 REAR BRACKET ATTACHMENT Step 1) Attach the rear brackets as shown in Figure 1, using a washer (E) and a nut (I) on each stud. Tighten each nut. MOUNTING THE STEP Step 2) Measure from the rear of the cab under body toward the front of the vehicle as shown in Figure 2. The first bolt hole location on the back side of the kick panel will be Dimension 'X' forward and Dimension 'Y' down (see Table 1) from the underbody seal as shown in Figure 2. The second bolt hole will be Dimension 'Z' forward, from the first hole, and Dimension 'Y' down (see Table 1) from the underbody seal. Mark both hole locations with a scribe or marker. Step 3) Center punch each of the marks and drill both holes using a 1/8" drill bit for a pilot followed by a 5/16" drill bit. Step 4) Mount the step bracket, as shown in Figure 3, by inserting the strap bolts through the underbody holes (remove rubber plugs as necessary) and bracket using a washer (D), a lockwasher (F), and a nut (H) on each stud. Cut off and discard the excess strap material from the strap bolts and reinsert the underbody hole plugs. For Front Door (passenger or driver side) installation, continue with Step 5. For Rear Door (passenger or driver side) installation, skip to Step 9. Figure 2: Under body kick panel looking from under vehicle REAR EDGE OF CAB Dimension 'X' FRONT OF VEHICLE Dimension 'Z' Dimension 'Y' Dimension 'Y' Dimension 'X' Dimension 'Z' Rear Door Bracket for Quad Cab Front Door Bracket Table 1: Suggested Dimension 'X', 'Y', and "Z' for Figure 2 2002-06 Dodge 1500 2002-06 Dodge 1500 Quad Cab FRONT DOOR ONLY FRONT DOOR REAR DOOR Dimension 'X' 35" 54 1/2" 22 1/2" Dimension 'Y' 2" 2" 1 3/4" Dimension 'Z' 10 1/2" 10 1/2" 6 3/4" Note: Verify that step placement is suitable for each application prior to drilling any holes. Suggested step placement is to have the middle of the step approximately equal with the front of the seat, with the step in the extended (down) position. Front Door Bracket Rear Door Bracket (Quad cab) Figure 3 Figure 4 Detail rear bracket Detail front bracket Figure 5 Maximum 0-2 o upward Front Door Step 5) Mount the step to the underbody bracket using a washer (D), a lockwasher (F), and a nut (H) on each stud. Step 6) Loosely assemble the support tabs to the rear brackets, as shown in Figure 4, using a bolt (B), two washers (D), a lockwasher (F), and a nut (H) on each bracket. Step 7) Hold the step so that the step tread is level or slightly angled upwards and mark, with a scribe or marker where the support tabs will mount to the underbody channel. For the front bracket, center punch the mark and drill using a 1/8" drill bit for a pilot followed by a 5/16" drill bit. Mount the bracket by inserting a strap bolt through the underbody hole and using a washer (D), a lockwasher (F), and a nut (H). Cut off and discard the excess strap material. Attach the rear bracket to the underbody support using the self-tapping screw (K) (see Figure 4). Step 8) Level the step tread so that it is parallel to the ground or tilted slightly upwards no more than 2 degrees (see Figure 5). Adjust the rear mounting brackets to accomplish this. When the step is level, tighten all fasteners. Check for any obstructions to the step. Complete the installation of the door switch and electrical connections, as detailed in the Electrical Installation Instructions. Figure 6 Detail rear bracket Figure 7 Maximum 0-2 o upward Quad Cab Rear Door Step 9) Mount the step to the underbody bracket using a washer (D), a lockwasher (F), and a nut (H) on each stud. Step 10) Loosely assemble the short angle brackets to the rear brackets, as shown in Figure 6, using a bolt (B), two washers (D), a lockwasher (F), and a nut (H) on each bracket. Step 11) Hold the step so that the step tread is level or slightly angled upwards and mark, with a scribe or marker where the short angle brackets will mount to the floor. Inside the vehicle, pull back the carpet where the bolt holes will be drilled. Under the vehicle, center punch the marks for the short angle brackets and drill using a 1/8" drill bit for a pilot followed by a 5/16" drill bit. Attach the short angle brackets to the floor using a bolt (B), two washers (D), a lockwasher (F), and a nut (H) on each bracket (see Figure 6). Step 12) Level the step tread so that it is parallel to the ground or tilted slightly upwards no more than 2 degrees (see Figure 7). Adjust the rear mounting brackets to accomplish this. When the step is level, tighten all fasteners. Step 13) Reinstall carpeting and interior trim as necessary. Check for any obstructions to the step. Complete the installation of the door switch and electrical connections, as detailed in the Electrical Installation Instructions. Detail front bracket 5/16 -18 x 3/4 Button head socket cap screw A 5/16 -18 x 1 Hex head cap screw B 1/4 -20 x 1 Hex head cap screw C 1/4 Split lock washer 5/16 Split lock washer 1/4 Flat washer G F E 5/16 Flat washer D 5/16 - 18 Hex nut 1/4 -20 Nylock hex nut 1/4 - 20 Nut-sert H I J 1/4 - Self-tapping screw K Fasteners Key: This kit may not require all fasteners shown in the following diagram. Refer to Fastener Kit chart above and instructions for specific fasteners used in this installation. Fastener Kit Required for these Kits: (Fronts) (Rears) 950220000 950220010 950221000 950221011 950220100 950220110 950221100 950221111 Fastener Key Letter Quantity Quantity A n/a na/ B 2 4 C n/a n/a D 9 12 E 4 4 F 7 8 G n/a n/a H 7 8 I 4 4 J n/a n/a K 1 n/a Tools required for installation Safety glasses Combination wrench and socket: 7/16" and 1/2” 3/16" Allen wrench 3/8 or 1/2” drive electric drill Drill bits: 1/8", 1/4", 5/16", 3/8" Phillips screwdriver Wire cutters Crimping tool for elec. terminals Measuring tape Marker or scribe Level Hammer Center punch ATTENTION: Before beginning any installation procedure, read all instructions carefully. Before drilling any holes make sure there is sufficient clearance on both sides. Step Assembly Step Assembly Left Rear Mounting Bracket Left Rear Mounting Bracket Right Rear Mounting Bracket Right Rear Mounting Bracket Short Angle Brackets (2) Short Angle Brackets (2) Front Adapter Mounting Bracket Front Adapter Mounting Bracket Front Step Hardware Rear Step Hardware

Transcript of REAR BRACKET ATTACHMENT Step 5) Step 1) Step 9 ... INSTALLATION INSTRUCTIONS Page 2 KODIAK...

Page 1: REAR BRACKET ATTACHMENT Step 5) Step 1) Step 9 ... INSTALLATION INSTRUCTIONS Page 2 KODIAK INSTALLATION INSTRUCTIONS Page 3 KODIAK INSTALLATION INSTRUCTIONS Page 4 Installation Instructions

KODIAK INSTALLATION INSTRUCTIONS Page 2 KODIAK INSTALLATION INSTRUCTIONS Page 3 KODIAK INSTALLATION INSTRUCTIONS Page 4

Installation Instructions

Fits:2002-06 Dodge Ram 1500, 2500, 35002002-06 Dodge Ram 1500 Quad CabFor Kodiak Kits#950220000 (front driver side, silver)#950221000 (front passenger side, silver)#950220010 (rear driver side, silver)#950221011 (rear passenger side, silver)#950220100 (front driver side, black)#950221100 (front passenger side, black)#950220110 (rear driver side, black)#950221111 (rear passenger side, black)

Hardware in each Kit1 Step Assembly1 Left rear mounting bracket1 Right rear mounting bracket2 Short angle brackets1 Fasteners Kit1 Front adapter mounting bracket

KODIAK INSTALLATION INSTRUCTIONS 1422135 / Rev. 0C © 05/08 Kwikee Products

Right Rear Mounting Bracket

Figure 1 REAR BRACKET ATTACHMENT

Step 1) Attach the rear brackets as shown in Figure 1,using a washer (E) and a nut (I) on each stud. Tighten each nut.

MOUNTING THE STEP

Step 2) Measure from the rear of the cab under body toward the front of the vehicle as shown in Figure 2. Thefirst bolt hole location on the back side of the kick panel will be Dimension 'X' forward and Dimension 'Y' down (see

Table 1) from the underbody seal as shown in Figure 2. The second bolt hole will be Dimension 'Z' forward, from the first hole, and Dimension 'Y' down (see Table 1) from the underbody seal. Mark both hole locations with a scribe or marker.

Step 3) Center punch each of the marks and drill both holes using a 1/8" drill bit for a pilot followed by a 5/16" drill bit.

Step 4) Mount the step bracket, as shown in Figure 3, by inserting the strap bolts through the underbody holes (remove rubber plugs as necessary) and bracket using a washer (D), a lockwasher (F), and a nut (H) on each stud. Cut off and discard the excess strap material from the strap bolts and reinsert the underbody hole plugs.

For Front Door (passenger or driver side) installation, continue with Step 5.For Rear Door (passenger or driver side) installation, skip to Step 9.

Figure 2: Under body kick panel looking from under vehicle

REAR EDGE OF CAB

Dimension 'X'

FRONT OF VEHICLE

Dimension'Z'

Dimension'Y'

Dimension'Y'

Dimension 'X'Dimension

'Z'

Rear Door Bracketfor Quad Cab Front Door Bracket

Table 1: Suggested Dimension 'X', 'Y', and "Z' for Figure 2

2002-06 Dodge 1500 2002-06 Dodge 1500 Quad Cab

FRONT DOOR ONLY FRONT DOOR REAR DOOR

Dimension 'X' 35" 54 1/2" 22 1/2"

Dimension 'Y' 2" 2" 1 3/4"

Dimension 'Z' 10 1/2" 10 1/2" 6 3/4"

Note: Verify that step placement is suitable for each application prior to drilling any holes. Suggested step placement is to have the middle of the step approximately equal with the front of the seat, with the step in the extended (down) position.

Front Door BracketRear Door Bracket(Quad cab)

Figure 3

Figure 4

Detail rear bracketDetail front bracket

Figure 5

Maximum 0-2o upward

Front Door

Step 5) Mount the step to the underbody bracket using a washer (D), a lockwasher (F), and a nut (H) on each stud.

Step 6) Loosely assemble the support tabs to the rear brackets, as shown in Figure 4,using a bolt (B), two washers (D), a lockwasher (F), and a nut (H) on each bracket.

Step 7) Hold the step so that the step tread is level or slightly angled upwards and mark,with a scribe or marker where the support tabs will mount to the underbody channel. For the front bracket, center punch the mark and drill using a 1/8" drill bit for a pilot followed by a 5/16" drill bit. Mount the bracket by inserting a strap bolt through the underbody hole and using a washer (D), a lockwasher (F), and a nut (H). Cut off and discard the excess strap material. Attach the rear bracket to the underbody support using the self-tapping screw (K)(see Figure 4).

Step 8) Level the step tread so that it is parallel to the ground or tilted slightly upwards no more than 2 degrees (see Figure 5). Adjust the rear mounting brackets to accomplish this. When the step is level, tighten all fasteners.

Check for any obstructions to the step. Complete the installation of the door switch and electrical connections, as detailed in the Electrical Installation Instructions.

Figure 6

Detail rear bracket

Figure 7

Maximum 0-2o upward

Quad Cab Rear Door

Step 9) Mount the step to the underbody bracket using a washer (D), a lockwasher (F), and a nut (H) on each stud.

Step 10) Loosely assemble the short angle brackets to the rear brackets, as shown in Figure 6, using a bolt (B), two washers (D), a lockwasher (F), and a nut (H) on each bracket.

Step 11) Hold the step so that the step tread is level or slightly angled upwards and mark, with a scribe or marker where the short angle brackets will mount to the floor. Inside the vehicle, pull back the carpet where the bolt holes will be drilled. Under the vehicle, center punch the marks for the short angle brackets and drill using a 1/8" drill bit for a pilot followed by a 5/16" drill bit. Attach the short angle brackets to the floor using a bolt (B), two washers (D), a lockwasher (F), and a nut (H) on each bracket (see Figure 6).

Step 12) Level the step tread so that it is parallel to the ground or tilted slightly upwards no more than 2 degrees (see Figure 7).Adjust the rear mounting brackets to accomplish this. When the step is level, tighten all fasteners.

Step 13) Reinstall carpeting and interior trim as necessary.

Check for any obstructions to the step. Complete the installation of the door switch and electrical connections, as detailed in the Electrical Installation Instructions.

Detail front bracket

5/16 -18 x 3/4 Button head socket cap screw

A

5/16 -18 x 1Hex head cap screw

B

1/4 -20 x 1Hex head cap screw

C

1/4 Split lock washer

5/16 Split lock washer

1/4 Flat washer

G

F

E

5/16 Flat washerD

5/16 - 18 Hex nut

1/4 -20 Nylock hex nut

1/4 - 20 Nut-sert

H

I

J

1/4 - Self-tapping screwK

Fasteners Key: This kit may not require all fasteners shown in the following diagram. Refer to Fastener Kit chart above and instructions for specific fasteners used in this installation.

Fastener Kit Required for these Kits:(Fronts) (Rears)

950220000 950220010950221000 950221011950220100 950220110950221100 950221111

FastenerKey Letter Quantity Quantity

A n/a na/B 2 4C n/a n/aD 9 12E 4 4F 7 8G n/a n/aH 7 8I 4 4J n/a n/aK 1 n/a

Tools required for installation

Safety glasses Combination wrench and

socket: 7/16" and 1/2” 3/16" Allen wrench 3/8 or 1/2” drive electric drill

Drill bits: 1/8", 1/4", 5/16", 3/8"Phillips screwdriverWire cuttersCrimping tool for elec. terminalsMeasuring tape

Marker or scribeLevelHammerCenter punch

ATTENTION:Before beginning any installation procedure, read all instructions carefully.

Before drilling any holes make sure there is sufficient clearance on both sides.

Step Assembly

Step Assembly

Left RearMounting Bracket

Left RearMounting Bracket

Right RearMounting Bracket

Right RearMounting Bracket

Short AngleBrackets (2)

Short AngleBrackets (2)

Front AdapterMounting Bracket

Front AdapterMounting Bracket

Front Step Hardware

Rear Step Hardware